Enhancing die corner accuracy through trim cut in WEDM

Selvakumar, G.; Jiju, K. Bravilin; Sarkar, Soumya; Mitra, S.

doi:10.1007/s00170-015-7606-0

Cited by 43 publications

(12 citation statements)

References 13 publications

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“…Degraded surface adversely affects mechanical properties such as fatigue strength, corrosion and wear resistance [12]. Therefore, multi-cut strategy is recommended in consideration of appropriate discharge energy, wire tension, wire feed and wire offset to eliminate surface and sub-surface defects [13][14][15]. Schematic representation of multi-cut strategy is shown in Fig.…”

Section: Introductionmentioning

confidence: 99%

Study of surface integrity and machining performance during main/rough cut and trim/finish cut mode of WEDM on Ti–6Al–4V: effects of wire material

Jadam

Datta

Masanta

2019

J Braz. Soc. Mech. Sci. Eng.

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Due to increased demand of dimensional accuracy and high precision of manufactured parts, wire electrical discharge machining (WEDM) became very popular, especially for 'difficult-to-cut' materials like titanium alloys. Grade 5 Ti alloy (Ti-6Al-4V) has enormous application in aerospace and biomedical fields. WEDM performance of Ti-6Al-4V is somewhat restricted due to its poor thermal conductivity, formation of hard and brittle carbide-/oxide-rich layer and often surface cracking which affect fatigue performance of the part product. Therefore, multi-cut strategy is adapted to mitigate machining-induced defects. The multi-cut mode consists of one main/rough cut followed by a number of trim/finish cuts. Aspects of surface integrity of the WEDMed Ti-6Al-4V obtained in different modes of cut are delineated in this reporting. Three slots are produced: (1) main cut; (2) main cut followed by one trim cut; and (3) main cut followed by two trim cuts using uncoated brass wire and zinc-coated brass wire, respectively. Surface morphology along with topographical features including roughness average, crack density, recast layer thickness, material immigration, residual stress and micro-indentation hardness is studied. Results obtained thereof are analysed with relevance to kerf width, material removal rate and wire wear.

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Section: Introductionmentioning

confidence: 99%

Study of surface integrity and machining performance during main/rough cut and trim/finish cut mode of WEDM on Ti–6Al–4V: effects of wire material

Jadam

Datta

Masanta

2019

J Braz. Soc. Mech. Sci. Eng.

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“…1. Selvakumar et al [21] already discussed the terminology dimensional shift (DS) which is the distance between the actual job profile and the path of rough cut (first cut). It is clearly indicated in Fig.…”

Section: Methods: Basics Of Trim Cuttingmentioning

confidence: 99%

“…During the rough cut, poor surface integrity and corner accuracy are a major concern which in turn reduces fatigue and corrosion properties of the WEDMed materials. By employing multi-pass cutting (i.e., one rough cut followed by multiple trim cut), it is possible to achieve better corner accuracy and surface integrity characteristics [19][20][21]. Despite few literatures [10,18] on WEDM of AA5083, no research work has been reported on the multipass cutting of AA5083 alloy in WEDM process.…”

Section: Introductionmentioning

confidence: 99%

Investigation on machining and surface characteristics of AA5083 for cryogenic applications by adopting trim cut in WEDM

Selvakumar¹,

Kuttalingam²,

Prakash³

2018

J Braz. Soc. Mech. Sci. Eng.

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This paper presents the experimental investigation on wire electrical discharge machining (WEDM) of aluminum alloy 5083 (AA5083), an exotic material widely used for cryogenic applications. In this work, an attempt has been made primarily to examine the influence of number of trim cuts on WEDM for the following responses: cutting speed, surface roughness, corner error and dimensional shift. AA5083 is one of the predominant materials used in cryogenic applications. It is inevitable to comprise the inherent property and surface quality of the material in cryogenic conditions. Hence, it is identified that cutting AA5083 in WEDM is a potential process. Taguchi methodology has been used for conducting the experiments. The present work has been focused on satisfying the customer needs and demands of acquiring the expected surface quality with maximum productivity. Experimental results proved that the rough cut followed with one optimal trim cut produces maximum cutting speed with good surface quality. Besides, an expression has been derived for calculating average cutting speed and effective cutting speed in trim cuts. Furthermore, the surface integrity of the rough cut and trim cut is compared and discussed with the SEM micrographs.

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“…A significant contribution was made by Selvakumar et al to achieve high corner accuracy during WEDM of Monel 400 alloy by using pulse parameter modification strategy 8 and trim cutting operation. 9 In view of enhancing corner accuracy, Sanchez et al 5 conducted experimental investigations based on the applications of path modification and cutting regime modification strategies. But, the work done by Selvakumar et al 8 concluded that the cutting regime modification strategy has some limitations and is not efficient enough to improve the corner accuracy.…”

Section: Introductionmentioning

confidence: 99%

“…But, the work done by Selvakumar et al 8 concluded that the cutting regime modification strategy has some limitations and is not efficient enough to improve the corner accuracy. By considering corner accuracy, a few researchers 3,7,9 have reported work on multi-pass cutting in WEDM.…”

Section: Introductionmentioning

confidence: 99%

Enhancing die corner accuracy using path modification strategy in wire electrical discharge machining of Monel 400

Selvakumar¹,

Kuttalingam²,

Selvaraj³

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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In this study, path modification strategy is used to improve the accuracy of the die corner produced in wire electrical discharge machining process. Based on Taguchi’s L18 array, experiments are performed on Monel 400 alloy. The influence of the machine-controllable factors such as wire tension, open-circuit voltage, pulse-on time, pulse-off time and additional travel and uncontrollable factors namely corner angles and flushing nozzle height on the performance measures such as surface roughness, cutting speed, and corner error are studied. The outcome of this study reveals that the path modification value in terms of additional travel of 0.5 mm improves the corner accuracy of the profile by 35% as compared to the profile machined without adopting path modification strategy. The analyses of scanning electron micrographs are carried out. Finally, an optimal technological guideline is reported for ready industrial use.

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Enhancing die corner accuracy through trim cut in WEDM

Cited by 43 publications

References 13 publications

Study of surface integrity and machining performance during main/rough cut and trim/finish cut mode of WEDM on Ti–6Al–4V: effects of wire material

Study of surface integrity and machining performance during main/rough cut and trim/finish cut mode of WEDM on Ti–6Al–4V: effects of wire material

Investigation on machining and surface characteristics of AA5083 for cryogenic applications by adopting trim cut in WEDM

Enhancing die corner accuracy using path modification strategy in wire electrical discharge machining of Monel 400

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